Net shape manufacturing using carbon nanotubes

Abstract

The present invention provides methods and systems for net shaped manufacturing using carbon nanotubes. Generally, an automatic control unit is used to place reaction units in the proper location to produce a component part of carbon nanotubes in a predetermined configuration. The reaction units include a carbon vaporization unit, a carbon feed/injection unit and a gas pressure/temperature control isolation unit. The carbon feed/injection unit advantageously operates to inject carbon based materials (e.g., graphite powder, solid graphite or carbon based gas) into an reaction area at a predetermined rate in which the carbon vaporization unit provides energy capable of dissociating carbon atoms from the injected carbon based material to produce a predetermined concentration of carbon vapor within the reaction area. The gas pressure/temperature control isolation unit operates to control the pressure and temperature of the reaction area to promote the growth of carbon nanotubes.

What is claimed is:  
     
         1 . A method of manufacturing a component part having a predetermined configuration using carbon nanotubes, comprising the steps of: 
 injecting carbon based material into a reaction area at a predetermined rate;    dissociating carbon atoms from said carbon based material at a predetermined rate;    isolating the reaction area at a predetermined temperature and a predetermined pressure, wherein said carbon nanotubes nucleate in said reaction area; and    dynamically locating said injecting, dissociating and isolating steps to nucleate said carbon nanotubes in said predetermined configuration.    
     
     
         2 . The method of  claim 1  further comprising the steps of: 
 decomposing said predetermined configuration into multiple cross-sectional layers; and  
 repeating said step of dynamically locating said injecting, dissociating and isolating steps for each said multiple cross-sectional layer, wherein each successive cross-sectional layer is stacked on a previous cross-sectional layer.  
 
     
     
         3 . The method of  claim 1  further comprising the step of dynamically varying a rate of injection of said carbon based material.  
     
     
         4 . The method of  claim 1  further comprising the step of dynamically varying a rate of dissociation from said carbon based material.  
     
     
         5 . The method of  claim 1  further comprising the step dynamically varying said predetermined pressure and predetermined temperature.  
     
     
         6 . The method of  claim 1 , wherein the step of dissociating is effectuated by a laser, an electron beam, or an electrical arc discharge unit.  
     
     
         7 . The method of  claim 1 , wherein said carbon based material further comprises a metal based material.  
     
     
         8 . The method of  claim 7 , further comprising the step of dynamically varying a concentration of said metal based material.  
     
     
         9 . The method of claim I further comprising the steps of: 
 injecting a carbon based material having a first metal based material; and    injecting a second carbon based material having a second metal based material.    
     
     
         10 . The method of  claim 1 , further comprising the step of adjusting a growth direction of said carbon nanotube during a growth period.  
     
     
         11 . A system of manufacturing a component part having a predetermined configuration using carbon nanotubes, comprising: 
 carbon injection unit, said carbon injection unit injecting a carbon based material into a reaction area;    carbon dissociation unit, said carbon dissociation unit dissociating carbon from said carbon based material;    isolation unit, said isolation unit controlling the pressure and temperature of said reaction area, wherein said carbon nanotubes nucleate within said reaction area; and    control unit in communication with and capable of dynamically locating said carbon injection unit, carbon dissociation unit and isolation unit in a predetermined pattern to nucleate said carbon nanotubes in said predetermined configuration.    
     
     
         12 . The system of  claim 11 , wherein said control unit further decomposing said predetermined configuration into multiple cross-sectional layers, wherein nucleation of said carbon nanotubes is repeated for each said multiple cross-sectional layer, and wherein each successive layer of carbon nanotubes is stacked on a previous layer.  
     
     
         13 . The system of  claim 11 , wherein said control unit further dynamically varies carbon based material injection rate.  
     
     
         14 . The system of  claim 13 , wherein said control unit further dynamically varies dissociation rate.  
     
     
         15 . The system of  claim 11 , wherein said control unit further dynamically varies said pressure and temperature of said reaction area.  
     
     
         16 . The system of  claim 11 , wherein said carbon dissociation unit comprises a laser, an electron beam and an electrical arc discharge unit.  
     
     
         17 . The system of  claim 11 , wherein said carbon based material further includes at least one type of metal based material.  
     
     
         18 . The system of  claim 17 , wherein said control unit further dynamically varies an amount and type of metal based material within said carbon based material.  
     
     
         19 . The system of  claim 12  further including a substrate capable of providing an initial nucleation surface for said carbon nanotubes.  
     
     
         20 . The system of  claim 19 , wherein said substrate includes seed material arranged in a predetermined pattern consistent with a first cross-sectional layer of said multiple cross-sectional layers.